Process variable transmitter with dual compartment housing
A process variable transmitter for use in an industrial control or monitoring process is provided and includes a housing with a cavity formed therein. The housing includes an integrated terminal block which defines first and second compartments in the cavity. The transmitter further includes a process variable sensor configured to sense a process variable of the industrial process. Measurement circuitry is carried in the first compartment and configured to receive a process variable signal from the process variable sensor and provide an output. An electrical connection is carried on the integrated terminal block in the second compartment and is electrically coupled to the output of the measurement circuitry.
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The present invention relates to industrial process control or monitoring systems. In particular, the present invention relates to process variable transmitters configured to sense process variables in such systems.
Process variable transmitters are used in industrial process control environments. Such transmitters couple to a process fluid to provide measurements related to the process. Process variable transmitters can be configured to monitor one or more process variables associated with fluids in a process plant, such as slurries, liquids, vapors and gasses in chemical, pulp, petroleum, gas, pharmaceutical, food and other fluid processing plants. Example monitored process variables include pressure, temperature, flow, level, pH, conductivity, turbidity, density, concentration, chemical composition or other properties of fluids. Typically, the process variable transmitters are located at remote locations, usually in a field, and send information to a centralized location such as a control room. Process variable transmitters sense process variables in a variety of applications, including oil and gas refineries, chemical storage tank farms, or chemical processing plants. In many instances, this requires the process variable transmitters to be located in a harsh environment.
Some types of process variable transmitters include a housing divided into two separate compartments. One compartment contains electrical circuitry and the other compartment contains a terminal block used to couple to a process control loop. One such configuration is shown in U.S. Pat. No. 5,546,804.
SUMMARYA process variable transmitter for use in an industrial control or monitoring process is provided and includes a housing with a cavity formed therein. The housing includes an integrated terminal block which defines first and second compartments in the cavity. The transmitter further includes a process variable sensor configured to sense a process variable of the industrial process. Measurement circuitry is carried in the first compartment and configured to receive a process variable signal from the process variable sensor and provide an output. An electrical connection is carried on the integrated terminal block in the second compartment and is electrically coupled to the output of the measurement circuitry.
The present invention provides a process variable transmitter for use in an industrial process, including a housing divided into two compartments. The two compartments are defined by an integrated terminal block which seals measurement circuitry in a first compartment and provides a seal between the two compartments.
Pursuant to one embodiment, process variable transmitter 12 includes a probe 19 which extends into process piping 18 and is configured to measure a process variable of a process fluid in the process piping 18. Example process variables include pressure, temperature, flow, level, pH, conductivity, turbidity, density, concentration, chemical composition, etc. Process variable transmitter 12 includes a housing 20 having a cavity 40 formed therein, which extends between a first opening 42 and a second opening 46. The first opening 42 preferably has a cylindrical shape such that an end cap 26 can be threadably coupled to the housing 20. A similar end cap 24 seals second compartment opening 46.
Single-compartment process variable transmitters are known. Such transmitters typically have an electronics module carried on a transmitter puck placed inside the housing which includes terminal connections. However, in a single compartment configuration, the interior electronics and other delicate components are exposed to the process environment when the cover is removed. Therefore, some prior art configurations use a dual compartment configuration in which the transmitter housing is divided into a first compartment and a second compartment by a bulkhead. An opening in the bulkhead is used to route wiring between the two compartments.
As shown in
Polymer wall 53 provides a seal between the first compartment 52 and the second compartment 50 in the cavity 40 formed in the housing 20. As shown in
As illustrated schematically in
With the present invention, the housing of a process variable transmitter is fabricated through a single molding step in which a polymer wall 53 provides a terminal block which is formed integrally with the housing. As used herein, the term “integrated terminal block” refers to the polymer wall 53 which divides a cavity in the housing of the transmitter 12 into two separate compartments. The molding which is used to simultaneously form the transmitter housing 20 including the polymer wall 53 may be any appropriate molding technique including injection molding. With this technique, the pins 57 which extend through the terminal block are fabricated integrally with the transmitter housing and extend through the terminal block/polymer wall 53. The pins 57 can be secured in place at the time housing 20 is molded, or at a subsequent time. In contrast to the prior art designs; the polymer wall provides a barrier between cavities 50 and 52 without requiring additional sealing such as o-rings, mechanical connections, etc. Similarly, the pins 57 can be positioned and secured through the polymer wall 53 without requiring additional insertion or sealing steps. This reduces the likelihood of any failure in the seal between the two cavities 50 and 52.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. Although a temperature sensor is shown, any type of process variable sensor may be employed. One example polymer is plastic. Any type of terminal may be placed in cavity 50 including sensor terminals, power terminals loop terminals, etc. The invention does not require both of terminals 59A and 59B to be located in cavity 50.
Claims
1. A process variable transmitter for use in an industrial process, comprising:
- a polymer housing having a cavity formed therein which extends between first and second openings, the housing including a polymer wall which forms an integrated terminal block molded integrally as a single piece with the housing and the polymer wall defines a first compartment and a second compartment in the cavity and provides a seal therebetween to seal the first compartment from an environment;
- a process variable sensor configured to sense a process variable of the industrial process;
- measurement circuitry carried in the first compartment which receives a process variable signal from the process variable sensor and provides an output;
- a plurality of terminal pins molded into the polymer wall which are electrically connected in the first compartment to the measurement circuitry and which extend from the first compartment to the second compartment, a portion of the plurality of pins in the first compartment extend from the polymer wall and are exposed in the first compartment and a portion of the plurality of pins in the second compartment extend from the polymer wall and are exposed in the second compartment; and
- a plurality of terminal screws assemblies connected to plurality of terminal pins, molded into the polymer wall and having terminal connections carried on the terminal block in the second compartment which are electrically coupled to the measurement circuitry by the plurality of terminal pins, wherein the plurality of terminal pins electronically connect to the process variable sensor in the second compartment.
2. The process variable transmitter of claim 1, including a terminal pin which extends through the polymer wall and provides an electrical connection between the measurement circuitry and a terminal connection.
3. The process variable transmitter of claim 2, wherein a terminal screw assembly is coupled to the terminal pin and disposed in the second compartment.
4. The process variable transmitter of claim 3, wherein the terminal screw assembly includes a prong which extends into the integrated terminal block to thereby secure the terminal screw assembly to the integrated terminal block.
5. The process variable transmitter of claim 1, wherein the terminal connectors provide an electrical connection to the process variable sensor.
6. The process variable transmitter of claim 1, wherein the terminal connectors provide an electrical connection to a two-wire process control loop.
7. The process variable transmitter of claim 3, including a screw configured to secure an electrical connection to the screw assembly.
8. The process variable transmitter of claim 1, wherein the process variable sensor comprises a temperature sensor.
9. A method for manufacturing a process variable transmitter for use in industrial process, comprising:
- molding a process variable transmitter polymer housing having a cavity formed therein and including a polymer wall which forms an integrated terminal block formed as a single piece with the housing and the polymer wall divides the cavity into a first compartment and a second compartment and provides a seal therebetween;
- providing a terminal screw assembly which is molded into the polymer wall and extends through the integrated terminal block;
- providing a terminal pin electrically connected to the terminal screw assembly which is molded into the polymer wall which provides an electrical connection which extends through the integrated terminal block from the first compartment to the second compartment, wherein a portion of the terminal pin in the first compartment extends from the polymer wall and is exposed in the first compartment and a portion of the terminal pin in the second compartment extends from the polymer wall and is exposed in the second compartment;
- placing measurement electronics in the first compartment and electrically coupling the measurement circuitry to the terminal screw assembly through the terminal pin in the first compartment; and
- coupling a process variable sensor to a terminal screw assembly in the second compartment, the terminal screw assembly electrically coupled to the electrical connection which extends through the integrated terminal block.
10. The method of claim 9, wherein the measurement circuitry couples to a two-wire process control loop through the electrical connection using the terminal screw assembly in the second compartment.
11. The method of claim 9, wherein the electrical connection comprises a terminal pin.
12. The method of claim 11, including securing the terminal screw assembly with a prong which extends into the integrated terminal block to thereby afix the terminal screw assembly to the integrated terminal block.
13. The method of claim 9, wherein the process variable sensor comprises a temperature sensor.
14. The method of claim 9, including sealing the first and second compartments with end caps.
15. The method of claim 9, including coupling a process control loop to terminal connectors in the second compartment.
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Type: Grant
Filed: Sep 24, 2013
Date of Patent: May 26, 2020
Patent Publication Number: 20150088277
Assignee: Rosemount Inc. (Shakopee, MN)
Inventors: Aaron Andrew Perrault (Shakopee, MN), Dirk Willy Bauschke (Shakopee, MN), Loren Michael Engelstad (Norwood, MN)
Primary Examiner: Carlos R Ortiz Rodriguez
Application Number: 14/035,019
International Classification: G05B 13/02 (20060101); G01D 11/24 (20060101); B29C 45/26 (20060101);